US20220256969A1 - Outsole plate - Google Patents

Abstract

A sole structure for an article of footwear includes a component including a first bundle of fibers affixed to a substrate, a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element, and a resin consolidating the first bundle of fibers and entrapping the connecting member to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application is a continuation of U.S. patent application Ser. No. 16/383,116, filed Apr. 12, 2019, which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Patent Application Ser. No. 62/658,195, filed Apr. 16, 2018, the disclosures of which are hereby incorporated by reference in their entireties.
TECHNICAL FIELD
• The present disclosure relates to articles of footwear including sole structures incorporating outsole plates.
BACKGROUND
• This section provides background information related to the present disclosure which is not necessarily prior art.
• Articles of footwear conventionally include an upper and a sole structure. The upper may be formed from any suitable material(s) to receive, secure, and support a foot on the sole structure. The upper may cooperate with laces, straps, or other fasteners to adjust the fit of the upper around the foot. A bottom portion of the upper, proximate to a bottom surface of the foot, attaches to the sole structure.
• Sole structures generally include a layered arrangement extending between a ground surface and the upper. One layer of the sole structure includes an outsole that provides abrasion-resistance and traction with the ground surface. The outsole may include an outsole plate formed of a rigid or semi-rigid material that provides rigidity and energy distribution across the sole structure. The outsole may be provided with one or more types of traction elements for maximizing engagement with a ground surface. In some cases, the traction elements may be fixed to the outsole plate. Alternatively, the traction elements may be interchangeable and/or may be formed from rubber or other materials that impart durability and wear-resistance, as well as enhancing traction with the ground surface.
DRAWINGS
• The drawings described herein are for illustrative purposes only of selected configurations and are not intended to limit the scope of the present disclosure.
• FIG. 1 is a side elevation view of an article of footwear in accordance with principles of the present disclosure;
• FIG. 2 is a cross-sectional view of the article of footwear ofFIG. 1, taken along section line2-2 ofFIG. 1;
• FIG. 3 is an exploded view of the article of footwear ofFIG. 1 showing an upper, a midsole, and an outsole;
• FIG. 4 is a bottom plan view of an outsole in accordance with principles of the present disclosure;
• FIG. 5A is a cross-sectional view of the outsole ofFIG. 4, taken along section line5-5 ofFIG. 4 and showing the outsole in an unmolded first state;
• FIG. 5B is a cross-sectional view of the outsole ofFIG. 4, taken along section line5-5 ofFIG. 4 and showing the outsole in a molded second state;
• FIG. 6A is an enlarged fragmentary view of the outsole plate ofFIG. 5A, taken at area6A ofFIG. 5A;
• FIG. 6B is an enlarged fragmentary view of the outsole plate ofFIG. 5B, taken atarea6B ofFIG. 5B;
• FIG. 7 is an enlarged fragmentary perspective view of a lower layer of an outsole plate in accordance with the principles of the present disclosure;
• FIG. 8 is an exploded view of a lower layer of an outsole plate in accordance with the principles of the present disclosure;
• FIGS. 9A-9E are views of various examples of arrangements of fiber strands used in forming support plies of the outsole ofFIG. 4;
• FIG. 10 is an exploded view of an upper layer of an outsole plate in accordance with the principles of the present disclosure;
• FIG. 11A-G are plan views of various examples of arrangements of fiber strands used in forming torsion plies of the outsole ofFIG. 4;
• FIG. 12A-12F are perspective views of various examples of a ground-engaging assembly of an outsole plate in accordance with the principles of the present disclosure;
• FIG. 13A is a perspective view of a mold for use in forming an outsole plate in accordance with the principles of the present disclosure, the mold shown in conjunction with a stack of outsole plate components prior to being assembled into an outsole plate;
• FIG. 13B is a cross-section view of the mold ofFIG. 13A, the mold shown in conjunction with a stack of outsole plate components enclosed within a mold cavity prior to a resin curing step;
• FIG. 13C is a cross-section view of the mold ofFIG. 13A, the mold shown in conjunction with a stack of fibers enclosed within a mold cavity after a resin curing step; and
• FIG. 13D is a perspective view of the mold ofFIG. 13A, the mold shown in conjunction with a formed outsole plate.
• Corresponding reference numerals indicate corresponding parts throughout the drawings.
DETAILED DESCRIPTION
• Example configurations will now be described more fully with reference to the accompanying drawings. Example configurations are provided so that this disclosure will be thorough, and will fully convey the scope of the disclosure to those of ordinary skill in the art. Specific details are set forth such as examples of specific components, devices, and methods, to provide a thorough understanding of configurations of the present disclosure. It will be apparent to those of ordinary skill in the art that specific details need not be employed, that example configurations may be embodied in many different forms, and that the specific details and the example configurations should not be construed to limit the scope of the disclosure.
• The terminology used herein is for the purpose of describing particular exemplary configurations only and is not intended to be limiting. As used herein, the singular articles “a,” “an,” and “the” may be intended to include the plural forms as well, unless the context clearly indicates otherwise. The terms “comprises,” “comprising,” “including,” and “having,” are inclusive and therefore specify the presence of features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof. The method steps, processes, and operations described herein are not to be construed as necessarily requiring their performance in the particular order discussed or illustrated, unless specifically identified as an order of performance. Additional or alternative steps may be employed.
• When an element or layer is referred to as being “on,” “engaged to,” “connected to,” “attached to,” or “coupled to” another element or layer, it may be directly on, engaged, connected, attached, or coupled to the other element or layer, or intervening elements or layers may be present. In contrast, when an element is referred to as being “directly on,” “directly engaged to,” “directly connected to,” “directly attached to,” or “directly coupled to” another element or layer, there may be no intervening elements or layers present. Other words used to describe the relationship between elements should be interpreted in a like fashion (e.g., “between” versus “directly between,” “adjacent” versus “directly adjacent,” etc.). As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items.
• The terms first, second, third, etc. may be used herein to describe various elements, components, regions, layers and/or sections. These elements, components, regions, layers and/or sections should not be limited by these terms. These terms may be only used to distinguish one element, component, region, layer or section from another region, layer or section. Terms such as “first,” “second,” and other numerical terms do not imply a sequence or order unless clearly indicated by the context. Thus, a first element, component, region, layer or section discussed below could be termed a second element, component, region, layer or section without departing from the teachings of the example configurations.
• One aspect of the disclosure provides a sole structure for an article of footwear. The sole structure includes a component including a first bundle of fibers affixed to a substrate, a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element. The sole structure further includes a resin consolidating the first bundle of fibers and entrapping the connecting member to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.
• Implementations of the disclosure may include one or more of the following optional features. In some examples, at least a portion of the connecting member is entangled in the first bundle of fibers.
• In some implementations, at least one of the first traction element, the second traction element, and the connecting member includes a projection extending in a direction toward the substrate. Here, the projection may be entangled in the fibers of the first bundle of fibers. In some examples, the projection includes a retention feature operable to engage the fibers of the first bundle of fibers. The retention feature may include at least one arm extending from a shaft, the shaft being received by and extending at least partially into the fibers of the first bundle of fibers. The least one arm may be formed substantially perpendicular to the shaft. Alternatively, the at least one arm is formed at an acute angle relative to the shaft. The at least one arm may extend from the shaft in a direction away from the substrate. In some examples, the shaft extends through a thickness of the first bundle of fibers.
• In some examples, the connecting member is at least partially covered by the resin.
• In some configurations, the sole structure includes a third traction element attached to at least one of the first traction element and the second traction element by at least one additional connecting member.
• In some examples, the first traction element and the second traction element are formed from nylon.
• In some implementations the first bundle of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.
• In some configurations, the first bundle of fibers is stitched to the substrate via stitching. Here, the first bundle of fibers includes first fibers comingled with second fibers, the second fibers including at least one of a different length, thickness, melting temperature, and Young's modulus than the first fibers. At least one of the stitching, the substrate, the first fibers, and the second fibers may comprise a thermoplastic material.
• In some examples, at least one of the fibers of the first bundle of fibers and the substrate comprise a thermoplastic material.
• In some implementations, the resin is a polymeric resin.
• The sole structure including any of the aforementioned features may be incorporated into an article of footwear. Here, the first traction element and the second traction element form a portion of a ground-engaging surface of the article of footwear.
• Another aspect of the disclosure provides a method of forming a sole structure for an article of footwear. The method includes attaching a first bundle of fibers to a flexible substrate, forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element, consolidating the first bundle of fibers with resin, and entrapping the connecting member with the resin to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.
• Implementations of the disclosure may include one or more of the following optional features. In some examples, the method includes entangling at least a portion of the connecting member in the first bundle of fibers.
• In other implementations, the method further includes providing at least one of the first traction element, the second traction element, and the connecting member with a projection that extends in a direction toward the substrate. Here, the method includes entangling the projection in the fibers of the first bundle of fibers. In some examples, the method includes providing at least one of the first traction element, the second traction element, and the connecting member with a projection includes providing a projection having a retention feature operable to engage the fibers of the first bundle of fibers. Here, providing a projection having a retention feature may include providing a retention feature having at least one arm extending from a shaft, the shaft being received by and extending at least partially into the fibers of the first bundle of fibers. Optionally, the method may include forming the at least one arm substantially perpendicular to the shaft. In some examples, the method includes forming the at least one arm at an acute angle relative to the shaft. Alternatively, the method includes forming the at least one arm from the shaft in a direction away from the substrate. The method may further include extending the shaft through a thickness of the first bundle of fibers.
• In some examples, the method includes at least partially covering the connecting member with the resin.
• In some implementations, the method includes providing the ground-engaging assembly with a third traction element attached to at least one of the first traction element and the second traction element by at least one additional connecting member.
• In some examples, the method includes forming the first traction element and the second traction element from nylon.
• In some examples, attaching a first bundle of fibers to a flexible substrate includes attaching a first bundle of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.
• Optionally, the method includes stitching the first bundle of fibers to the substrate via stitching. Attaching a first bundle of fibers to a flexible substrate includes attaching a first bundle of fibers including first fibers comingled with second fibers, the second fibers including at least one of a different length, thickness, melting temperature, and Young's modulus than the first fibers. The method may include forming at least one of the stitching, the substrate, the first fibers, and the second fibers from a thermoplastic material.
• In some implementations, the method includes forming at least one of the fibers of the first bundle of fibers and the substrate from a thermoplastic material.
• In some examples, consolidating the first bundle of fibers with resin includes consolidating the first bundle of fibers with a polymeric resin.
• In some configurations, the method may include incorporating the sole structure of any of the preceding claims into an article of footwear. Here, the method may include forming a portion of a ground-engaging surface of the article of footwear with the first traction element and the second traction element.
• In some examples, forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member includes forming the first traction element, the second traction element, and the connecting member using additive manufacturing.
• In some examples, the method includes forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member includes forming the first traction element, the second traction element, and the connecting member via three-dimensional (3D) printing.
• The method may further include inserting the ground-engaging assembly into a first mold portion. Here, inserting the ground-engaging assembly into the first mold portion includes inserting at least one of the first traction element, the second traction element, and the connecting member into a recess of the first mold portion. The method may also include positioning the first bundle of fibers in contact with the ground-engaging assembly within the first mold portion. In some examples, the method includes compression molding the first bundle of fibers and the ground-engaging assembly to form the sole structure.
• In some examples, consolidating the first bundle of fibers with resin includes consolidating the first bundle of fibers with thermoplastic resin comingled with the first bundle of fibers. Here the method may include applying heat to the first bundle of fibers to cause the thermoplastic resin to flow.
• Another aspect of the disclosure includes sole structure for an article of footwear. The sole structure is formed by a process comprising the steps of attaching a first bundle of fibers to a flexible substrate, forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element, consolidating the first bundle of fibers with resin, and entrapping the connecting member with the resin to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.
• Implementations of the disclosure may include one or more of the following optional features. In some examples least a portion of the connecting member is entangled in the first bundle of fibers.
• In some implementations, at least one of the first traction element, the second traction element, and the connecting member includes a projection extending in a direction toward the substrate. Here, the projection is entangled in the fibers of the first bundle of fibers. Optionally, the projection may include a retention feature operable to engage the fibers of the first bundle of fibers. In some examples, the retention feature includes at least one arm extending from a shaft, the shaft being received by and extending at least partially into the fibers of the first bundle of fibers. The at least one arm may be formed substantially perpendicular to the shaft. In some examples, the at least one arm is formed at an acute angle relative to the shaft. In some configurations, the at least one arm extends from the shaft in a direction away from the substrate. Optionally, the shaft extends through a thickness of the first bundle of fibers.
• In some implementations, the connecting member is at least partially covered by the resin.
• In some examples, a third traction element may be attached to at least one of the first traction element and the second traction element by at least one additional connecting member.
• In some configurations, the first traction element and the second traction element are formed from nylon.
• In some examples, the first bundle of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers. In some implementations, the first bundle of fibers is stitched to the substrate via stitching. Here, the first bundle of fibers includes first fibers comingled with second fibers, the second fibers including at least one of a different length, thickness, melting temperature, and Young's modulus than the first fibers. At least one of the stitching, the substrate, the first fibers, and the second fibers may include a thermoplastic material.
• In some examples, at least one of the fibers of the first bundle of fibers and the substrate comprise a thermoplastic material. The resin of the sole structure may be polymeric resin.
• Some aspects of the disclosure provides an article of footwear incorporating the sole structure of any of the preceding paragraphs. Here, the first traction element and the second traction element form a portion of a ground-engaging surface of the article of footwear.
• Referring toFIGS. 1-3, an article offootwear10 includes an upper100 andsole structure200. The article offootwear10 may be divided into one or more regions. The regions may include aforefoot region12, amid-foot region14, and aheel region16. Theforefoot region12 may be subdivided into a toe portion corresponding with phalanges, and a ball portion associated with metatarsal bones of a foot. Themid-foot region14 may correspond with an arch area of the foot, and theheel region16 may correspond with rear portions of the foot, including a calcaneus bone. Thefootwear10 may further include ananterior end18 associated with a forward-most point of theforefoot region12, and aposterior end20 corresponding to a rearward-most point of theheel region16. A longitudinal axis A_Fof thefootwear10 extends along a length of thefootwear10 from theanterior end18 to theposterior end20, and generally divides thefootwear10 into amedial side22 and alateral side24. Accordingly, themedial side22 and thelateral side24 respectively correspond with opposite sides of thefootwear10 and extend through theregions12,14,16.
• The upper100 includes interior surfaces that define an interior void102 configured to receive and secure a foot for support onsole structure200. The upper100 may be formed from one or more materials that are stitched or adhesively bonded together to form the interior void102. Suitable materials of the upper may include, but are not limited to, mesh, textiles, foam, leather, and synthetic leather. The materials may be selected and located to impart properties of durability, air-permeability, wear-resistance, flexibility, and comfort.
• In some examples, one ormore fasteners110 extend along the upper100 to adjust a fit of the interior void102 around the foot and to accommodate entry and removal of the foot therefrom. The upper100 may includeapertures112 such as eyelets and/or other engagement features such as fabric or mesh loops that receive thefasteners110. Thefasteners110 may include laces, straps, cords, hook-and-loop, or any other suitable type of fastener. The upper100 may include atongue portion114 that extends between the interior void102 and the fasteners.
• With reference toFIGS. 2 and 3, in some examples the upper100 includes astrobel104 having a bottom surface opposing thesole structure200 and top surface formed on an opposite side from the bottom surface and defining afootbed106 of the interior void102. Stitching or adhesives may secure the strobel to the upper100. Thefootbed106 may be contoured to conform to a profile of the bottom surface (e.g., plantar) of the foot. Optionally, the upper100 may also incorporate additional layers such as aninsole108 or sockliner that may be disposed upon thestrobel104 and reside within the interior void102 of the upper100 to receive a plantar surface of the foot to enhance the comfort of the article offootwear10. An ankle opening116 in theheel region16 may provide access to the interior void102. For example, the ankle opening116 may receive a foot to secure the foot within the interior void102 and to facilitate entry and removal of the foot from and to the interior void102.
• With reference toFIGS. 2 and 3, the sole structure includes amidsole202 and anoutsole204. Generally, themidsole202 is disposed intermediate theoutsole204 and the upper100, and is configured to attenuate forces associated with impact of thesole structure200 with a ground surface. Themidsole202 may extend fully or partially along a length of thefootwear10. In some examples themidsole202 may be fragmentary, such that a plurality of midsole segments are distributed along thesole structure200. Stitching or adhesives may secure themidsole202 to the upper100.
• Themidsole202 may be formed from any suitable materials that compress resiliently under applied loads. Examples of suitable polymer materials for the foam materials include ethylene vinyl acetate (EVA) copolymers, polyurethanes, polyethers, and olefin block copolymers. The foam can also include a single polymeric material or a blend of two or more polymeric materials including a polyether block amide (PEBA) copolymer, the EVA copolymer, a thermoplastic polyurethane (TPU), and/or the olefin block copolymer.
• Theoutsole204 includes anupper surface206 and a ground-engagingsurface208 formed on an opposite side from theupper surface206. Theoutsole204 is a full-length outsole204, and extends continuously from afirst end210 at theanterior end18 of thefootwear10 to asecond end212 at theposterior end20, and from themedial side22 to thelateral side24.
• With reference theFIGS. 2-6B, components of theoutsole204 include anoutsole plate214, one or morefirst traction elements216, and a webbed ground-engagingassembly218. As discussed in greater detail below, theoutsole204 is formed by joining each of thecomponents214,216,218 together using acurable resin220. For example, theoutsole plate214, thefirst traction elements216, and the ground-engagingassembly218 may be disposed within a mold cavity and subjected to a combination of pressure and heat, whereby theresin220 is delivered to the mold cavity and impregnates and/or encapsulates each thecomponents214,216,218 to form a unitary structure. Accordingly, theoutsole plate214, thefirst traction elements216, and the webbed ground-engagingassembly218 may cooperate to define the ground-engagingsurface208 of theoutsole204.
• With reference toFIGS. 2 and 4, theoutsole plate214 extends from thefirst end210 to thesecond end212. In the illustrated example, theoutsole plate214 is a full-length plate. Accordingly, thefirst end210 of theoutsole plate214 is coincident with theanterior end18 of thefootwear10, while thesecond end212 is coincident with theposterior end20 of the footwear. Alternatively, theoutsole plate214 may be a partial-length plate that extends from theanterior end18 to an intermediate portion of thefootwear10. Additionally or alternatively, theoutsole plate214 may be fragmentary, and include a plurality of individual segments disposed along the sole structure.
• With reference toFIGS. 2-6B, theoutsole plate214 is formed of a one ormore layers221,222 stacked in series and bonded together by theresin220. In one example, theoutsole plate214 includes alower layer221 and anupper layer222, as shown inFIGS. 2 and 3. As explained in greater detail below, each of thelayers221,222 includes at least one ply223,224 formed from one ormore strands226,226a-226coffibers227 arranged on substrates228 in selected patterns to impart stiffness and gradient load paths throughout theoutsole plate214. Each of thelower layer221 and theupper layer222 may be formed with various quantities and arrangements of the plies223,224 to impart desired torsional properties to theoutsole plate214. Accordingly, thelower layer221 and theupper layer222 are generically represented inFIGS. 2 and 3, while examples of configurations of the plies223,224 for each of thelayers221,222 are described below. With continued reference toFIGS. 2 and 3, thelower layer222 of theoutsole plate214 is provided with preformedapertures225 for receiving thetraction elements216, as discussed below.
• Eachstrand226 may refer to a tow of a plurality offibers227, a monofilament, yarn, or polymer pre-impregnated tows. As used herein, the term “tow” or “strand” refers to a bundle (i.e., plurality of filaments (e.g., fiber) that may be twisted or untwisted and each tow may be designated a size associated with a number offibers227 the corresponding tow contains. For instance, asingle strand226 may range in size from about 1,000 fibers per bundle to about 48,000 fibers per bundle.
• In some configurations, thefibers227 associated with eachstrand226 include at least one of carbon fibers, boron fibers, glass fibers, and polymeric or thermoplastic fibers.Fibers227 such as carbon fibers, aramid fibers, and boron fibers may provide a high Young's modulus while glass fibers (e.g., fiberglass) and polymer fibers (e.g., synthetic fibers) provide a medium modulus. Additionally or alternatively, eachstrand226 may be provided withfirst fibers227 comingled withsecond fibers227, whereby thesecond fibers227 have one or more of a different length, thickness, melting temperature, and/or Young's modulus than thefirst fibers227. For example, thestrand226 may include a plurality ofcarbon fibers227 and a plurality ofpolymeric resin fibers227 that, when activated, solidify and hold thecarbon fibers227 in a desired shape and position relative to one another.
• As used herein, the substrate228 refers to any one of a veil, carrier, or backer to which at least onestrand226 offibers227 is attached. The substrate228 may be formed from a thermoset polymeric material or a thermoplastic polymeric material and can be a textile (e.g., knit, woven, or non-woven), an injection molded article, an organosheet, or a thermoformed article.
• Thestrands226 offibers227 forming the plies223,224 of eachlayer221,222 may be affixed to the same or separate substrates228 and embroidered in a layered configuration. If thestrands226 offibers227 are applied to separate substrates228, the individual substrates228 are stacked on top of one another once each substrate228 is supplied with astrand226 offibers227. If, on the other hand, only one substrate228 is utilized in forming theoutsole plate214, afirst strand226 offibers227 is applied to the substrate228 withadditional strands226 of fibers227 (i.e., layers) being applied on top of thefirst strand226. Finally, a single,continuous strand226 offibers227 may be used to form theoutsole plate214, whereby thestrand226 is initially applied and affixed to the substrate228 and is subsequently layered on top of itself to form a layered construction.
• When forming thelayers221,222 of theoutsole plate214, the strand orstrands226 of the plies223,224 may be applied directly to the substrate228, and may be attached to the substrate228 usingstitching230 to hold thestrands226 in a desired location. In some examples, thestitching230 may include a continuous zig-zag stitch extending along the strand. Alternatively, thestitching230 may be provided at discrete attachment points spaced along thestrand226.
• Thestitching230 may be formed from the same material as the substrate228. Alternatively, thestitching230 may be formed from a different material than the material forming the substrate228 such that thestitching230 is associated with a higher melting point than the substrate228. Providing thestitching230 with a higher melting point than the substrate228 allows thestitching230 to melt after the substrate228 when heat is applied during formation of theoutsole plate214. In some examples, thestitching230, or at least a portion thereof, is formed from a thermoplastic material.
• With reference toFIGS. 5A, 6A, 7, and 8, thelower layer221 of the illustrated example includes asubstrate228,228apositioned on top of thelower layer221, a first support ply223eadjacent to and beneath thesubstrate228b, and a second support ply223cbeneath the first support ply223e. With the illustrated example, both of the support plies223c,223eare beneath thesubstrate228band are attached to the substrate22b8 using a single “pass” ofstitching230, whereby eachstitch230 secures bothplies223c,223e. However, as discussed above, the first support ply223emay be stitched to thesubstrate228bseparately from the second support ply223c. Further, although support plies223c,223ehaving strands226 extending transverse to each other are illustrated, any combination of the support plies223a-223edescribed below may be used in thelower layer221.
• Referring toFIGS. 9A-9E, several examples of configurations of the support plies223 are shown. As shown, the support plies223 of theoutsole plate214 each include at least onesupport ply strand226,226awound in a uniform serpentine configuration, such that the support plystrands226aeach include a plurality oflinear segments232 arranged in parallel. Each of thesegments232 is straight and is connected to adjacent ones of thesegments232 byloops234 at each end. In some examples, the support plystrands226amay be tightly wound, whereby eachsegment232 abuts an adjacent one of thesegments232 to provide a substantially continuous layer of the support plystrands226a. In some examples, the support plystrands226amay be wound loosely, wherebyadjacent segments232 are separated from each other by a gap (not shown). In some examples, thesegments232 may be equally spaced from each other. However, spacing betweensegments232 may be variable, such that some segments are spaced farther apart from each other than others. Additionally, somesegments232 may be spaced apart from each other, whileother segments232 abut each other.
• As shown inFIGS. 9A-9E, thesegments232 may extend parallel to or at an oblique angle Φ to the longitudinal axis A_F. For example, a longitudinal axis A_Sof thesegments232 may extend at oblique angles to the longitudinal axis A_Franging from −30 degrees (−30°) to 30 degrees (30°). In one example, thesegments232 may be oriented at +/−30 degrees (30°) relative to a longitudinal axis A_Fof the article offootwear10, as shown inFIGS. 9C and 9E. In another example, thesegments232 of thesupport ply strand226amay be arranged at an angle Φ of +/−15 degrees (15°) relative to a longitudinal axis A_Fof the article offootwear10, as shown inFIGS. 9B and 9D. Other angles may be selected to impart desired stiffness to theoutsole plate214.
• As introduced above, thelower layer221 includes a plurality ofapertures225 formed therethrough. Each of theapertures225 is configured to receive a portion of one of thetraction elements216 therethrough when thecomponents216,218,221,222 of theoutsole plate214 are assembled prior to molding. As shown inFIG. 7, theapertures225 may be formed through thesubstrate228aand each of the support plies223. As discussed above, thesubstrate228ais formed of a substantially continuous sheet of material. Accordingly, theapertures225 may be formed in thesubstrate228aby material removal methods, such as cutting or punching. Conversely, theapertures225 are formed through the support plies223 by stitchingadjacent segments232 of the support plystrands226aof each support ply223 to be spaced apart from each other in discrete areas of thelower layer221. As shown inFIG. 7, thelower layer221 may include an increased density ofstitching230 around each of theapertures225 so that thesegments232 follow an arcuate path to define an outer periphery of theaperture225. Accordingly, a first one of theapertures225 is defined by (i) an opening that is cut or punched through the material of thesubstrate228a, (ii) a first space between twoadjacent segments232 of asupport ply strands226aof a first one of the plies223, and (iii) a second space between two adjacent support plystrands226aof a second one of the plies223, whereby each of the opening, the first space, and the second space are in communication with each other and cooperate to define an uninterrupted passage through thelower layer221. Additional openings or spaces may be formed where additional substrates228 or plies223,224 are included in thelower layer221.
• Turning now toFIGS. 5A, 6A, and 10-11G, example configurations of theupper layer222 are provided. In addition to support plies223 described above, theupper layer222 of theoutsole plate214 further includes one or more torsion plies224. Unlike the support plies223, which have a substantially continuous and homogenous arrangement of adjacently-laidelongate segments232 of support plystrands226a, the torsion plies224 are formed fromtorsion strands226barranged in irregular patterns to impart anisotropic stiffness and gradient load paths throughout theoutsole plate214.
• The torsion plies224 may further includeperipheral strands226cinterweaved with thetorsion strands226balong an outer perimeter of the torsion plies224, whereby theperipheral strands226care configured to define an outer peripheral edge P of the torsion plies224 when thetorsion strands226bare trimmed, as described below. Accordingly, theperipheral strand226cof each of the torsion plies224 may advantageously provide a continuous boundary of theoutsole plate214. The continuousperipheral strand226cprovides improved strength along peripheral edge P of theoutsole plate214, and minimizes exposed ends of the trimmedtorsion strands226b.
• With reference toFIGS. 5A, 6A, and 10, theupper layer222 includes one of thesubstrates228,228bdefining a base of theupper layer222 for receiving a plurality of the plies223,224. The plies223,224 of theupper layer222 include afirst support ply223,223cstacked adjacent to thesubstrate228b, a pair of torsion plies224,224astacked in series atop thefirst support ply223,223c, and asecond support ply223,223edisposed on an opposite side of theupper layer222 from thesubstrate228b. Thus, theupper layer222 is arranged such the torsion plies224 are interposed between the support plies223. Although the illustratedupper layer221 includes two torsion plies224,224ahaving the same configuration, any one of the examples of the torsion plies224a-224gdescribed below may be used. Additionally or alternatively, different combinations of the torsion plies224,224a-224gmay be interposed between different combinations of the support plies223,223a-223e.
• Referring toFIGS. 11A-11G, the torsion plies224 of theoutsole plate214 each include at least onetorsion strand226,226bwound in an a non-uniform, serpentine configuration, such that eachtorsion strand226bincludes a plurality of arcuate segments236 distributed anisotropically throughout the ply224,224a-224g. With reference toFIGS. 11A-11G each of the segments236 includes arcuate portions and is initially connected to adjacent ones of the segments236 byloops238 at each end. Unlike the support plies223, which have a plurality of linear, uniformly distributed segments, the segments236 of the torsion plies224 include arcuate portions, and are variably spaced apart from each other.
• Thetorsion strands226bof the torsion plies224 may include a plurality ofmedial segments236a, a plurality oflateral segments236b, and/or a plurality ofinterior segments236c. As shown, the segments236a-236care generally arranged in a splayed pattern such that an average spacing between the segments236a-236cis greater in theforefoot region12 and theheel region16 than it is in themid-foot region14. For instance, in the example ofFIGS. 11A-11G, thesegments236aare tightly spaced through themid-foot region14, and diverge from each other along a direction from themid-foot region14 towards each of theanterior end18 and theposterior end20. Due to the spacing between adjacent segments236a-236cof thetorsion strand226bbeing closer in themid-foot region14 compared to the spacing in the forefoot andheel regions12,16, respectively, the segments236a-236ccollectively provide a greater concentration/density offibers227 in themid-foot region14 compared to the concentration/density offibers227 in the forefoot andheel regions12,16, respectively. Accordingly, thetorsion strands226bof the torsion plies224,224a-224gmay provide theoutsole plate214 with a stiffness in themid-foot region14 that is greater than the stiffness of theoutsole plate214 in each of theforefoot region12 and theheel region16.
• As discussed below, the ends240,241 of adjacent ones of the segments236a-236cmay be initially connected to each other byloops238 such that asingle torsion strand226bforms themedial segments236a, thelateral segments236b, and theinterior segments236c. In the examples ofFIGS. 11A-11D, thetorsion strand226bincludes theloops238 disposed outside a peripheral edge P of thetorsion ply224,224afor connecting adjacent segments236a-236cof thetorsion strand226b. As discussed above, the peripheral edge P is defined by aperipheral strand226cextending along an outer perimeter of theply224,224a. Theperipheral strand226cmay be interweaved through the segments236 of thetorsion strand226b.
• To eliminate the presence of pinch points when subjecting the torsion plies224 to pressure (e.g., molding) to form theoutsole plate214, thetorsion strand226bmay be trimmed along theperipheral strand226cto form a continuous peripheral edge P of the torsion ply224. With reference to the examples of the torsion plies224,224e-224gshown inFIGS. 11E-11G, thetorsion strands226bmay be contained within the peripheral edge P of the ply224,224e-224g. Here, theloops238 may be consolidated when thestrands226 and other plies223,224 are subjected to heat and pressure to consolidate thefibers227, and thereby form theoutsole plate214.
• Referring toFIG. 11A, in one example of thetorsion ply224,224aatorsion strand226bis wound continuously in an overlapping pattern, whereby amedial segments236aextend from themedial side22 in theforefoot region12 to thelateral side24 in theheel region16. Each of themedial segments236athen wraps around theheel region16 to themedial side22, and transitions into a correspondinglateral segment236bthat extends from themedial side22 in theheel region16 to thelateral side24 in theforefoot region12. As discussed above, each oflateral segments236bextends beyond theperipheral strand226cin theforefoot region12. Aloop238 is formed where thestrand lateral segment236bis turned back towards theperipheral strand226cto extend back towards themedial side22 in theheel region16, around theheel region16 to thelateral side24, and back to themedial side22 in theforefoot region12, where anotherloop238 is formed. This pattern is continued until the segments236,236a-236care distributed along an entirety of the ply223,223 from themedial side22 to thelateral side24. In some examples, themedial segments236a, thelateral segments236b, and theinterior segments236cmay alternatingly interweave or overlap each other as thetorsion strand226bis laid, thereby forming a basket weave configuration in themid foot region14. Additionally or alternatively, all of themedial segments236amay be laid above or beneath all of thelateral segments236b.
• In another example of atorsion ply224,224b—shown inFIG. 11B—thetorsion strand226bis arranged such that the segments236,236a-236cextend generally along a longitudinal axis A_Fof the article offootwear10. Themedial segments236aare generally disposed on themedial side22 of thetorsion ply224,224band extend fromfirst ends240aat themedial side22 in theforefoot region12 to second ends241aat themedial side22 in theheel region16. One or more of themedial segments236ahave a reverse curve shape, such that each of themedial segments236acurves towards thelateral side24 through theforefoot region12 and curves towards the medial side through themid-foot region14 and/or theheel region16.
• Thelateral segments236bare generally disposed on thelateral side24 of the torsion ply224band extend fromfirst ends240cat thelateral side24 in theforefoot region12 to second ends241cat themedial side22 in theheel region16. Thelateral segments236beach extend along a simple or compound curve from the first ends240cto the second ends241c. Accordingly, thelateral segments236bmay be described as being “C-shaped.”
• Theinterior segments236care generally disposed intermediate themedial side22 and thelateral side24 and extend fromfirst ends240bat theanterior end18 to second ends241bat theposterior end20. One or more of theinterior segments236chave a reverse curved shape, such that each of the segments curves towards thelateral side24 in theforefoot region12, is substantially straight through themid-foot region14, and curves towards themedial side22 through theheel region16. Accordingly, theinterior segments236cmay be described as being “S-shaped.”
• Referring to the example of thetorsion ply224,224cshown inFIG. 11C, thetorsion strand226bmay be formed from acontinuous strand226 offibers227 or two ormore strands226 offibers227. As shown, thetorsion strand226bof thetorsion ply224,224cincludesloops238 disposed outside theperipheral strand226cof theply224,224cfor connectingadjacent segments236,236a,236bof thetorsion strand226b.
• Thetorsion strand226bincludes a plurality ofmedial segments236aand a plurality oflateral segments236bthat interweave or overlap within aninterior region242 of theply224c. As shown, theinterior region242 is formed in themidfoot region14 and is spaced inwardly from each of themedial side22 and thelateral side24.
• Themedial segments236amay be disposed adjacent and substantially parallel to one another, whereby eachmedial segment236ahas a length that extends between afirst end240aproximate to theperipheral strand226cat themedial side22 in theforefoot region12, and asecond end241aproximate to theperipheral strand226cat the lateral side124 in theheel region16. Themedial segments236atraverse theply224cin the shape of a reverse “C”, whereby an intermediate portion of each of themedial segments236apasses through theinterior region242. Here, the portions of themedial segments236ain themidfoot region14 extend in a direction substantially parallel to the longitudinal axis A_Fof the article offootwear10. In some implementations, the spacing between each adjacentmedial segment236ais substantially uniform across the lengths of themedial segments236a.
• On the other hand, eachlateral segment236bhas a corresponding length that extends between afirst end240bproximate to theperipheral strand226cat thelateral side24 in theforefoot region12, and asecond end241bproximate to theperipheral strand226cat thelateral side24 in theheel region16. The shape of thelateral segments236bare inverted relative to the shape of themedial segments236a, and therefore traverse theply224cin the shape of a “C”, whereby an intermediate portion of each of thelateral segments236bpasses through theinterior region242. Here, the portions of thelateral segments236bin themidfoot region14 extend in a direction substantially parallel to the longitudinal axis A_Fof the article offootwear10.
• Themedial segments236aextending into and out of theinterior region242 may cross-cross, overlap, and/or interweave with one or more of thelateral segments236bextending into and out of theinterior region242. While the spacing between each adjacentmedial segment236amay be substantially uniform across the lengths of themedial segments236a, eachmedial segment236amay be disposed between two correspondinglateral segments236bin an alternating fashion within theinterior region242. Accordingly, themedial segments236aand thelateral segments236bof the torsion ply224cmay extend substantially parallel to the longitudinal axis A_Fwithin theinterior region242 and diverge away from one another when extending toward their respective ends at one of the lateral andmedial sides22,24, respectively. In some implementations, the example of the torsion ply224cprovides theupper layer222 with a greater concentration/density offibers227 within theinterior region242 compared to the concentration/density of fibers outside theinterior region242, thereby increasing the stiffness of theoutsole plate214 within theinterior region242.
• As shown inFIG. 11C, the torsion ply224cincludes a void243,243ain theforefoot region12 and a void243,243bin theheel region16 where thefibers227 are absent. In some examples, the voids243 expose one or more plies223,224 or substrates228 situated adjacent to the torsion ply224c. When incorporated in a layered configuration to form thelayers221,222, the torsion ply224cdoes not impart any stiffness properties in the areas of theforefoot region12 and theheel region16 where thevoids243a,243bare formed.
• FIG. 11D provides a top view of another example of atorsion ply224,224dthat may be used in one of thelayers221,222. The pattern of thetorsion strand226bis shown relative to a peripheral edge P of thefinished outsole plate214, which may be defined by aperipheral strand226c. As with the previous examples of torsion plies224, thetorsion ply224,224dmay be formed from a correspondingcontinuous torsion strand226bor two ormore torsion strands226b, and may include at least one of carbon fibers, aramid fibers, boron fibers, glass fibers, and polymer fibers.FIG. 11D shows the torsion ply224dincluding correspondingloops238 for connecting adjacent segments236,236a-236cof thetorsion strand226b. Theloops238 disposed in theforefoot region12 are disposed inside theperipheral strand226c, while theloops238 proximate to theheel region16 are disposed outside theperipheral strand226c. To eliminate the presence of pinch points when subjecting the torsion ply224dto pressure (e.g., molding) to form theoutsole plate214, theloops238 proximate to theheel region16 are cut along theperipheral strand226cto remove the presence ofloops238 extending outside theperipheral strand226c.
• Compared to examples of the torsion plies224,224a-224cdescribed above, the torsion ply224dofFIG. 11D provides a greater variance in stiffness across the length of theoutsole plate214.Interior segments236cof theply224dextend substantially parallel to the longitudinal axis A_Ffrom theheel region16 to themidfoot region14, while segments along thelateral side22 and themedial side24 converge toward theinterior region242 of theoutsole plate214 when extending from theheel region16 to themidfoot region14. As a result, the torsion ply224dincludes a spacing between adjacent segments236,236a-236cin theheel region16 that decreases as the segments236,236a-236cextend into themidfoot region14, whereby themidfoot region14 of theoutsole plate214 is associated with greater density offibers227 than theheel region16.
• In some configurations, the segments236 disperse into four discrete groups of segments236 when extending from themidfoot region14 to the first ends240 disposed in theforefoot region12 of the torsion ply224d. For instance, a group ofmedial segments236agenerally follows theperipheral strand226cof the torsion ply224dat themedial side22, while a group oflateral segments236bgenerally follows theperipheral strand226cof the torsion ply224dat thelateral side24. Moreover, a first group ofinterior segments236cis disposed adjacent and spaced inward from the group of themedial segments236a, and a second group ofinterior segments236cis disposed adjacent and spaced inward from the group of thelateral segments236b. In the example shown, the first and second groups ofinterior segments236care also spaced apart from one another. Accordingly, the torsion ply224dincludesmultiple voids243cbetween the groups of segments236 where thefibers227 are absent, thereby exposing one or more plies223,224 or substrates228 that may be situated adjacent to the torsion ply224din theforefoot region12. Here, thelayer221,222 associated with the torsion ply224ddoes not impart any stiffness properties in the areas of theforefoot region12 where the presence offibers227 are absent. Each group of segments236 corresponds to a respective “tendon” imparting stiffness properties based on the number of segments and/or spacing between adjacent segments in each discrete group. More specifically, the discrete groups of segments236 cooperate to impart anisotropic stiffness and gradient load paths through theforefoot region12 of theoutsole plate214. For instance, the longitudinal stiffness and the transverse stiffness taken at different locations in theforefoot region12 may alternate between some magnitude of stiffness provided by theconcentration fibers227 in the corresponding group and no stiffness where the presence offibers227 is absent.
• In some examples, themedial segments236aare shorter than the first group ofinterior segments236cadjacent to themedial segments236a, the first group ofinterior segments236care shorter than the second group ofinterior segments236cadjacent to thelateral segments236b, and the second group ofinterior segments236care longer than the group oflateral segments236b. In some configurations, at least one of the groups of segments236 includes a different number of segments236 than the other groups. In other configurations, each group of segments includes the same number of segments236 as the other groups. Increasing the number of segments236 in a corresponding group provides a greater concentration offibers227 and, thus, imparts a greater stiffness for the corresponding group.
• In some implementations, the spacing between adjacent segments236 in at least one of the groups varies across the length of the torsion ply224dbetween themidfoot region14 and the first ends240 in theforefoot region12. For instance, the spacing between adjacent segments236 in at least one of the groups may increase as the segments236 traverse into theforefoot region12 from themidfoot region14, and then the spacing may gradually decrease until the segments terminate at the correspondingloops238 in theforefoot region12. In other implementations, the spacing between adjacent segments236 in at least one of the groups is substantially uniform across the length of the torsion ply224dbetween themidfoot region14 and theloops238 in theforefoot region12.
• Due to the spacing between adjacent segments236 of the torsion ply224dbeing closer in themidfoot region14 compared to the spacing in theheel region16, the torsion ply224bcollectively provides a greater concentration/density offibers227 in themidfoot region14 compared to the concentration/density offibers227 in theheel region16. Moreover, due to the segments236 branching out into four discrete groups while traversing the torsion ply224dfrom themidfoot region14 to theforefoot region12, the concentration/density offibers227 in themidfoot region14 is greater than the density offibers227 in theforefoot region12 where thefibers227 are absent in thevoids243cbetween each discrete group of segments236. Accordingly, the torsion ply224dimparts different stiffness properties to theoutsole plate214 in each of the forefoot, midfoot, andheel region12,14,16, respectively.
• FIG. 11E shows another example of atorsion ply224,224ethat may be used in thelayers221,222. The pattern of thetorsion strand226 is shown relative to a peripheral edge P of thefinished outsole plate214. The torsion ply224eis substantially similar to the torsion ply224dshown inFIG. 11D, except that segments236,236a-236coffibers227 are shorter than the corresponding segments236,236a-236cof the torsion ply224d. For instance, the torsion ply224eincludes segments236 having a shortened length, wherebyfibers227 are absent in a majority of both theforefoot region12 and theheel region16.
• Theinterior segments236cof the torsion ply224eextend substantially parallel to the longitudinal axis A_Ffrom correspondingloops238 disposed in theheel region16, whilesegments236a,236bcloser to themedial side22 and thelateral side24 converge toward theinterior region242 of the footwear when extending from the correspondingloops238 disposed in theheel region16. However, in contrast to the torsion ply224dhaving adjacent segments236 that extend across the width of themidfoot region14, the segments236 forming the torsion ply224eare concentrated toward the interior region of the torsion ply224ewithin themidfoot region14, while defining gaps along the peripheral edge P where thefibers227 are absent and, thus, not imparting stiffness.
• Similar to the torsion ply224d, the segments236 of the torsion ply224ealso disperse into four discrete groups of segments236 when extending from themidfoot region14 to theloops238 disposed in at least one of theforefoot region12 or themidfoot region14. For instance, a group ofmedial segments236agenerally follows theperipheral strand226cof the torsion ply224dat themedial side22 and terminate in theforefoot region12, while a group oflateral segments236bgenerally follows theperipheral strand226cof the torsion ply224dat thelateral side24 and terminate in themidfoot region14. Moreover, a first group ofinterior segments236cis adjacent and spaced inward from the group ofmedial segments236a, and a second group ofinterior segments236cis adjacent and spaced inward from the group of thelateral segments236b. Accordingly, the torsion ply224eincludesmultiple voids243dbetween the groups of segments236 where thefibers227 are absent, thereby exposing one or more plies223,224 or substrates228 that may be situated adjacent to the torsion ply224din theforefoot region12. Here, torsion ply224edoes not impart any stiffness properties in thevoids243din theforefoot region12 between the groups of segments236. However, the discrete groups of segments236 cooperate to impart anisotropic stiffness and gradient load paths in regions extending toward theforefoot region12 and away from the high concentration/density offibers227 in themidfoot region14, where the magnitude of stiffness is greatest.
• In some examples, the group ofmedial segments236aare shorter than the first group ofinterior segments236c, the first group ofinterior segments236care shorter than the second group ofinterior segments236c, and the second group ofinterior segments236care shorter than the group oflateral segments236b. In some configurations, at least one of the groups of segments236 includes a different number of segments236 than the other groups. In other configurations, each group of segments236 includes the same number of segments236 as the other groups. Increasing the number of segments236 in a corresponding group provides a greater concentration offibers227 and, thus, imparts a greater stiffness for the corresponding group. Additionally, the spacing between adjacent segments236 in at least one of the groups may vary or may be substantially uniform as the segments traverse toward theforefoot region12 of the torsion ply224e. For instance, the spacing between segments236 in at least one of the groups may initially increase as the segments begin to traverse toward theforefoot region12 from themidfoot region14, and then the spacing may gradually decrease until the segments236 terminate at the correspondingloops238 in theforefoot region12 or in themidfoot region14 at a location proximate to theforefoot region12.
• FIG. 11F provides a top view of a fifth example of atorsion ply224fthat may be used in either of thelayers221,222. The pattern of thetorsion strand226bof the torsion ply224fis shown relative to a peripheral edge P of thefinished outsole plate214. The torsion ply224fmay be formed from onecontinuous torsion strand226bor from two ormore strands226 offibers227.
• FIG. 11F shows the torsion ply224fhaving a plurality of segments236 having the same length extending between a first location L₁disposed in theforefoot region12 and a second location L₂disposed in theheel region16. Thetorsion strand226bincludesloops238 disposed at the first location L₁and the second location L₂for connecting adjacent segments236. In the example shown, thesegments236aproximate to themedial side22 of theply224fconverge toward the interior of theply224fwhen extending from the second location L₂toward themedial region14, and then diverge and fan out away from the interior of theply224fwhen extending from themedial region14 to the first location L₁. Thus, thesegments236aproximate themedial side22 generally follow the curvature of theperipheral strand226cof the torsion ply224fat themedial side22. Conversely, thesegments236bof the torsion ply224fproximate to thelateral side24 of theply224fand within the interior of theoutsole plate214 extend substantially parallel to one another and substantially parallel to the longitudinal axis A_Fbetween the first location L₁and the second location L₂. The converging by thesegments236aproximate to themedial side22 into the interior of the torsion ply224fcauses the spacing betweenadjacent segments236ain themedial region14 of the plate to decrease and, thus, provide a greater magnitude of stiffness in themidfoot region14 due to the corresponding increase in the concentration/density offibers227. Moreover, the spacing between each adjacent segment236 of the torsion ply224fis greater in theforefoot region12 proximate to the first location L₁compared to the spacing between eachadjacent segment236ain theheel region16 proximate to the second location L₂. Accordingly, the torsion ply224fprovides theheel region16 with a magnitude of stiffness that is less than the magnitude of stiffness in themidfoot region14 and greater than the magnitude of stiffness in theforefoot region12. In other configurations, the spacing between each adjacent segment236 of the torsion ply224fis substantially uniform across the lengths of the segments236 between the first location L₁and the second location L₂.
• FIG. 11G provides a top view of a sixth example of a configuration of a torsion ply224gthat may be used in thelayers221,222 of theoutsole plate214. The pattern of the sixth example of the torsion ply224gis shown relative to a peripheral edge P of thefinished outsole plate214. In the example shown, torsion ply224gis formed from onecontinuous torsion strand226b. However, in other examples, the torsion ply224gmay be formed from two ormore strands226 offibers227.
• FIG. 11G shows atorsion strand226bof the torsion ply224fhaving a plurality of segments236,236a-236cthat each extend along the length of theply224ffrom a first location L₁disposed in theheel region16 to a corresponding second, third, and fourth locations L₂, L₃, L₄disposed in theforefoot region12 of theoutsole plate214. For instance,lateral segments236bextend between the first location L₁and the corresponding second location L₂, whilemedial segments236aextend between the first location L₁and the corresponding fourth location L₄disposed closer to thefirst end210 of theoutsole plate214 than the second location L₂corresponding to thelateral segments236b. Additionally,interior segments236cdisposed between themedial segments236aand thelateral segments236bextend between the first location L₁and the corresponding third location L₃. In the example shown, the third location L₃corresponding to theinterior segments236cis disposed closer to thefirst end210 of theoutsole plate214 than the second location L₂corresponding to thelateral segments236band further away from thefirst end210 of theoutsole plate214 than the fourth location L₄corresponding to themedial segments236a. Thetorsion strand226bincludesloops238 disposed at each location L₁-L₄for connecting adjacent segments236 of the torsion ply224f
• In some implementations, the corresponding second, third, and fourth locations L₂, L₃, L₄cooperate to define a terminal end the torsion ply224fin theforefoot region12 that aligns with an anatomical feature of the foot when the foot is received upon theoutsole plate214 within the article offootwear10. In some examples, the anatomical feature includes a bend line of all the toes of the foot. The bend line may extend through the metatarsal-phalangeal (MTP) joints of the foot where proximal phalanges of the toes meet corresponding metatarsals of the foot. Accordingly, each segment236 may impart stiffness to theoutsole plate214 under the wearer's foot up to the MTP joints without imparting any stiffness in areas of theoutsole plate214 where the toes of the foot reside to provide desirable flexibility during athletic movements.
• Themedial segments236amay be disposed adjacent and substantially parallel to one another along the longitudinal axis A_Fof theoutsole plate214 proximate to theperipheral strand226cat themedial side22. In some examples, the spacing between each adjacentmedial segment236ais substantially uniform across the length of themedial segments236abetween the first location479 and the fourth location L₄. In other examples, the spacing between each adjacentmedial segment236avaries across the length such that the spacing between each adjacentmedial segment236ais closer within themidfoot region14 compared to the spacing within the forefoot andheel regions12,16, respectively.
• Thelateral segments236bmay be disposed adjacent and substantially parallel to one another along the longitudinal axis A_Fof theoutsole plate214 proximate to theperipheral strand226cat thelateral side24. In some examples, the spacing between eachadjacent lateral segment236bis substantially uniform across the length of thelateral segments236bbetween the first location L₁and the second location L₂. In other examples, the spacing between eachadjacent lateral segment236bvaries across the length such that the spacing between eachadjacent lateral segment236bis closer within themidfoot region14 compared to the spacing within the forefoot andheel regions12,16, respectively. Providing a narrower spacing between adjacent segments offers a greater concentration/density offibers227 to thereby increase the stiffness of theoutsole plate214.
• Within interior regions of theoutsole plate214, theinterior segments236cmay be disposed adjacent and substantially parallel to one another along the longitudinal axis A_Fof theoutsole plate214. As with themedial segments236aand thelateral segments236b, the spacing between each adjacentinterior segment236cmay be substantially uniform or may vary across the length of theinterior segments236cbetween the first location L₁and the third location L₃.
• In some configurations, the segments236a-236cof the torsion ply224gare disposed adjacent and substantially parallel to one another within the midfoot andheel regions14,16, respectively, and then disperse from one another when extending from themidfoot region14 to each of the corresponding second, third, and fourth locations L₂, L₃, L₄disposed in theforefoot region12. For instance, themedial segments236amay generally follow the contour of theperipheral strand226cof the torsion ply224gat themedial side22, thelateral segments236bmay generally follow the contour of theperipheral strand226cof the torsion ply224gat thelateral side24, and theinterior segments236cmay extend substantially parallel to the longitudinal axis A_Fas the lateral andmedial segments236a,236bdiverge outward and away from theinterior segments236c. Here, the torsion ply224fdoes not impart any stiffness properties in thevoids243din theforefoot region12 between the segments236,236a-236cwhere thefibers227 are absent. However, the dispersing of the segments236,236a-236cof the torsion ply224gimparts anisotropic stiffness and gradient load paths in regions extending into theforefoot region12 and away from the high concentration/density of fibers450 in themidfoot region14, whereat the magnitude of stiffness is highest.
• As set forth above, one or more of at least one of the torsion plies224,224a-224gofFIGS. 11A-11G may be incorporated intoupper layer222 or thelower layer221 to tune stiffness properties imparted by thefinished outsole plate214.
• With continued referenceFIGS. 3-6B, thefirst traction elements216 include aflange244 and a ground-engagingprojection246 extending from theflange244. In one example, theflange244 is substantially cylindrical in shape, and may include a plurality of notches or apertures formed through a thickness thereof. In some examples, theflange244 may include a plurality of radially-arranged tabs or notches configured to engage thecomponents220,222,223 of the outsole plate214 (i.e. layers221,222 and resin220) to prevent rotation of thefirst traction elements216 within theoutsole plate214. Theprojection246 extends axially from theflange244, and may taper in width along a direction from theflange244 to a distal end. As shown, theprojection246 is conical in shape. However, theprojection246 may be pyramidal, or have other geometries.
• As shown inFIGS. 5A-6B, in one example thefirst traction element216,216amay be formed as a unitary body, whereby theflange244,244aand theprojection246,246aare integrally formed with each other. Additionally or alternatively, one or more of thefirst traction elements216,216bmay be fragmentary, whereby theprojection246,246bis configured to be removably attached to theflange244,244b. For example, theflange244,244bmay be an anchor portion having a first cleat-retention feature247aand theprojection246,246bmay be a separately-formed cleat having a second cleat-retention feature247bconfigured to cooperate with the first cleat-retention feature247aof theflange244,244b. In one example, the first cleat-retention feature247amay be a female-threaded bushing, while the second cleat-retention feature247bis a male-threaded stud. Accordingly, thedifferent projections246 can be attached to theflange244 to provide desired traction characteristics to theoutsole204. Theoutsole204 may include only unitaryfirst traction elements216a, only fragmentaryfirst traction elements216b, or a combination of unitaryfirst traction elements216aand fragmentaryfirst traction elements216b.
• In addition to thefirst traction elements216, theoutsole204 may also include the ground-engagingassembly218 including a plurality oftraction elements248 interconnected with each other by respective connectingmembers250. As shown inFIGS. 12B-12F, the ground-engaging assembly may include a plurality offasteners252 extending therefrom, which are configured to engage one or more of the plies223,224 to secure the ground-engagingassembly218 to theoutsole204 prior to molding.
• As best shown inFIG. 4, thetraction elements248 of the ground-engagingassembly218 may be described as being chevron-shaped, and include a pair ofwings254 extending in opposite directions from acentral portion256. In some examples, at least one of thewings254 may include a compound taper, whereby a width of thewing254 tapers along a first direction—parallel to the ground-engaging surface—from thecentral portion256 to aterminal end258, and along a second direction—perpendicular to the ground-engaging surface—from a base260 to adistal edge262.
• As shown inFIGS. 12A-12F, the ground-engagingassembly218,218a-218fincludes one of the connectingmembers250 extending between each pair ofadjacent traction elements248. Accordingly, eachtraction element248 may be connected to a plurality ofadjacent traction elements248 by respective connectingmembers250, such that the connectingmembers250 and thetraction elements248 form a web or network. For example, a first one of thetraction elements248 may be connected to a second one of thetraction elements248 by a first connectingmember250, and connected to a third one of thetraction elements248 by a second connectingmember250. Thicknesses of the connectingmembers250 may be selected to impart desired properties of strength and stability to the ground-engagingassembly218. For instance, the connectingmembers250aof the example of the ground-engagingassembly218ashown inFIG. 12A have a greater thickness than the connectingmembers250b-fof the examples of the ground-engaging assembly shown inFIGS. 12B-12F.
• In the illustrated example, the ground-engagingassembly218 includes a continuous network of connectingmembers250 andtraction elements248 extending along an entire length of theoutsole204. However, in other examples, the ground-engagingassembly218 may be fragmentary, and include a first sub-network oftraction elements248 and connectingmembers250 disposed in afirst region12,14,16 and a separately formed, second sub-network oftraction elements248 and connectingmembers250 disposed in asecond region12,14,16.
• As provided above, in some examples, the ground-engagingassembly218,218b-218ffurther includes a plurality of thefasteners252 configured to engage one or more of the plies223,224 to secure the ground-engagingassembly218 to thelayers221,222 during assembly of theoutsole204, as discussed below. Thefasteners252 project from the connectingmembers250 in an opposite direction from thetraction elements248. As shown inFIGS. 12B-12F, some examples of thefasteners252 include ashaft266 extending from one of the connectingmembers250 and a retention feature268 disposed at a distal end of theshaft266.
• In a first example of the ground-engagingassembly218,218b-218, the retention feature268 of thefastener252b-252eis an arm268a-268dextending from the distal end of theshaft266. In one example of thefastener252b, the arm268amay be curved to provide rounded, hook-shapedarms268b. In other examples of thefastener252c-252e, thearm268c-268emay be elongate and extend along a longitudinal axis at a relative angle to a longitudinal axis of theshaft266. For example, a longitudinal axis of thearm268cmay be arranged at an acute angle with respect to a longitudinal axis of theshaft266 to provide a hook-shapedretention feature268chaving a tapered or flared profile for being inserted through the plies223,224 to capture one or more of thestrands226. In other examples, the longitudinal axis of thearm268dmay be perpendicular to the longitudinal axis of theshaft266. Additionally or alternatively, the longitudinal axis of thearm268emay extend at an obtuse angle with respect to the longitudinal axis of theshaft266, whereby thearm268eextends away fromtraction elements248.
• In another example of the ground-engagingassembly218,218f, the retention feature268 is ananchor268fdisposed at the distal end of theshaft266. For example, theanchor268fmay include a body having a greater width than theshaft266 so that theanchor268fengages one or more of thestrands226 of theplies222,224 when theoutsole204 is assembled. In the illustrated example, theanchors268fare cylindrical or disc-shaped bodies having a greater diameter than theshaft266. However, other shapes ofanchors268fmay be used, as desired. Although the illustrated examples of the ground-engagingassembly218,218b-218feach include a single type of thefastener252,252b-252f, some examples may include multiple types of thefasteners252,252b-252f. For example, the ground-engagingassembly218 may include somefasteners252 havingarms268b-268eandother fasteners252 havinganchors268f, as shown inFIGS. 5A-6B.
• The ground-engagingassembly218 may be formed using additive manufacturing methods, such as three-dimensional (3D) printing. For example, the ground-engaging assembly may be 3D printed of a polymeric material, such as nylon. By forming the ground-engagingassembly218 using a three-dimensional printing process, thetraction elements248, connectingmembers250, andfasteners252 can be easily modified for different applications. Furthermore, the three-dimensional printing process allows thefasteners252 to be formed with complex geometries not capable of being formed using traditional molding processes. For example, ground-engagingassemblies218 havingfasteners252 that are formed with hook-shapedarms268a,268bor anchors268eare difficult to manufacture using traditional molding processes, as thearms268a,268band anchors268emay cause the ground-engagingassembly218 become to fixed within a mold cavity. Additionally, three-dimensional printing allows thetraction elements248 to be customized on an individual basis to accommodate different users, sports, and playing surfaces.
• With particular reference toFIGS. 13A-13D, formation of theoutsole204 is described in conjunction with amold1000. Themold1000 includes anupper mold plate1002 and alower mold plate1004. Themold plates1002,1004 define amold cavity1006 having the desired shape of theoutsole204 to allow themold1000 to impart the desired shape of theparticular outsole204 to theplies222,224. Themold cavity1006 may include one ormore fixtures1008 for securing thefirst traction elements216 within themold1000. For example, thefixtures1008 may be magnetic and include conical cavities for receiving theprojections246 of thefirst traction elements216. The benefits of theretainers1008 are twofold. First, thefixtures1008 align thefirst traction elements216 within the mold to ensure proper spacing and arrangement. Secondly, thefixtures1008 secure thefirst traction elements216 within themold cavity1006 when theresin220 is introduced, and prevent thefirst traction elements216 from floating within theresin220.
• Initially, each of thelower layer221 and theupper layer222 may be fabricated using desired combinations of the substrates228 and plies223,224 discussed above. Once thelayers221,222 are assembled, theloops238 may be trimmed to provide a continuous outer peripheral edge P of eachlayer221,222, as shown inFIG. 11A. In addition to fabricating thelayers221,222, thelower layer221 may be provided with thefirst traction elements216.
• With each of thelayers221,222 fabricated, thefirst traction elements216, the ground-engagingassembly218,lower layer221, and theupper layer222 may be arranged and assembled to form a layup of theoutsole204. In some examples, thecomponents216,218,221,222 of theoutsole204 may be assembled outside of themold cavity1006, and then positioned within themold cavity1006 as an assembly. Alternatively, themold cavity1006 may function as an assembly fixture, whereby thecomponents216,218,221,222 can be stacked within themold cavity1006. For example, thelower mold plate1004 may include features corresponding to the shapes of thetraction elements248 of the ground-engagingassembly218 so that the ground-engagingassembly218 can be positioned within themold cavity1006.
• With continued reference toFIGS. 5A, 6A, and 11A,lower layer221 is initially stacked upon the ground-engagingassembly218. In addition to providing for handling of the ground-engaging assembly, the connectingmembers250 may collectively provide a support bed for thelayers221,222. When present, theshafts266 may be received through one or more of the plies223,224 such that thefasteners252 of the ground-engagingassembly218 engage a top side of at least one of the plies223,224 as thelower layer221 is stacked atop the ground-engaging assembly. Particularly, thefasteners252 may become entangled with thefibers227 of one or more of the plies223,224 to secure the ground-engaging assembly to theplies222,224. A length of theshaft266 of each of thefasteners252 may be selected depending on a thickness of each of the plies223,224 and a desired engagement between thefasteners252 and the plies223,224. Accordingly, one or more of thefasteners252 may engage the support plies223 of thelower layer221. Additionally or alternatively, one or more of the fasteners may engage the plies223,224 of theupper layer222.
• Thefirst traction elements216 may be provided to theoutsole204 lay-up at any time prior to theupper layer222, regardless of whether theoutsole204 is assembled outside of themold cavity1006 or inside of themold cavity1006. For example, thefirst traction elements216 may be provided to theapertures225 of thelower layer221 before or after thelower layer221 is stacked atop the ground-engagingassembly218. As discussed above, once thefirst traction elements216 are received within themold cavity1006, theprojections246 of thefirst traction elements216 are engaged by thefixtures1008 formed in themold cavity1006 to align and secure thefirst traction elements216 within themold1000.
• As discussed above, in some examples thefirst traction elements216amay each be formed as unitary bodies having aflange244aand aprojection246aprotruding from theflange244a. In this configuration, theprojection246 of each of thefirst traction elements216 may be inserted through theapertures225 of thelower layer221 so that theprojections246 are received through thesubstrate228aand thestrands226, as shown inFIGS. 5A and 6A. Accordingly, theprojections246 will project from the ground-engagingsurface208 of theoutsole204. As theprojections246 of each of thefirst traction elements216 are inserted through theapertures225, theflanges244 of each of thefirst traction elements216 engage or abut an upper surface of thesubstrate228aof thelower layer221. In other examples, an upper surface of thelower layer221 may be defined by one of the plies223,224, and theflanges244 of each of thefirst traction elements216 may abut or become entangled within thestrands226 of the plies223,224. Additionally or alternatively, theoutsole204 may be constructed with one or more of the fragmentaryfirst traction elements216b, whereby theflange244band theprojection246bare provided tooutsole204 in a pre-assembled state.
• Once thefirst traction elements216 are inserted in thelower layer221, theupper layer222 is layered upon thelower layer221 in a back-to-back arrangement, such that thesubstrate228aof thelower layer221 is on top and contacts thesubstrate228bof theupper layer222, as shown inFIGS. 5A and 6A. Accordingly, theflanges244 of thefirst traction elements216 are interposed between theupper layer222 and thelower layer221. More specifically, theflanges244 of thefirst traction elements216 are disposed between and contact thesubstrate228aof thelower layer221 and thesubstrate228bof theupper layer222. In some examples, the torsion plies224a,224bmay be stacked in a back-to-face arrangement, whereby the plies223,224 of each of thelayers221,222 are arranged atop therespective substrates228a,228b, and thesubstrate228bof theupper layer222 contacts thestrand226 of theplies222,223 of thelower layer221, or vice-versa. Alternatively, thelayers221,222 may be arranged face-to-face, whereby the plies223,224 of eachlayer221,222 face inward towards each other such that theplies222,223 of thelower layer221 and theplies222,223 of theupper layer222 are in facing contact with each other.
• As discussed above, the one or more of thefasteners252 of the ground-engagingassembly218 may also be configured to engage the plies223,224 of theupper layer222 thereby securing each of the ground-engagingassembly218, thelower layer221, thefirst traction elements216, and theupper layer222 as a single assembly for placement into themold cavity1006. Additionally, or alternatively, the connectingmembers250 and/or thetraction elements248 of the ground-engagingassembly218 may be entangled with thestrands226 of one or more of thelayers221,222 to secure a position of the ground-engagingassembly218 with respect to the one or more of thelayers221,222.
• As shown inFIG. 13B, the assembledcomponents216,218,221,222 of theoutsole204 are inserted between themold plates1002,1004 within themold cavity1006. At this point, themold1000 is closed by moving themold plates1002,1004 toward one another or by moving one of themold plates1002,1004 toward theother mold plate1002,1004. It should be noted that while theplies222,224 are described as being pre-impregnated with resin material, theplies222,224 could additionally be supplied withresin220 that is infused within themold1000 via aninlet1010 once themold plates1002,1004 are closed. Additionally or alternatively, theresin220 may be poured into themold cavity1006 prior to closing themold1000. The injected or pouredresin220 could be in addition to the impregnated resin of thestrands226, or alternatively, could be used in place of the impregnatedresin220.
• Once closed, themold1000 applies heat and pressure to thestacked layers221,222 disposed within themold cavity1006 to activate theresin220 associated with thestrands226. The heat and pressure applied to thestacked layers221,222 causes the particular shape of themold cavity1006 to be imparted to the stacked plies222,224 and, once cured, theresin220 associated with thestacked layers221,222 to harden and retain the desired shape. Additionally, thehardened resin220 at least partially encapsulates thetraction elements248, the connectingmembers250 of the ground-engagingassembly218 to attach to the ground-engagingassembly218 to theoutsole204, as shown inFIGS. 5B, 6B, and 13C.
• The foregoing processes may be used to form outsole plates that may be used to manufacture custom-made footwear. For instance, various measurements relating to forces applied by an athlete during use of the article of footwear may be taken into consideration in determining an optimal configuration of the ground-engaging assembly. The customized ground-engaging assembly may be provided as a unitary assembly including thetraction elements248, the connectingmembers250, and thefasteners252 and easily assembled to one ormore plies222,224 ofcomposite fibers227 without the need for custom molding hardware.
• Custom outsole plates may further allow for tailoring of the stiffness of the plate for a particular wearer of the footwear. For instance, the tendon stiffness and calf muscle strength of an athlete may be measured to determine a suitable stiffness of the plate for use by the athlete. Here, the stiffness of the outsole plate can vary with the strength of the athlete or for the size/condition of the athlete's tendons. Additionally or alternatively, the stiffness of the plate may be tailored based on biomechanics and running mechanics of a particular athlete, such as how the angles of the athlete's joints change during running movements. In some examples, force and motion measurements of the athlete are obtained before manufacturing a custom plate for the athlete. In other examples, plates are manufactured in particular ranges or increments of stiffness to provide semi-custom footwear such that individual athletes may select a suitable stiffness.
• In addition to improved performance characteristics, the described implementations of thesole structure200 provide improved manufacturability of customized footwear by facilitating a modular approach to assembly. For example, any one or more of thecomponents216,218,222,224 may be substituted for an alternative corresponding component providing different dimensional and/or material properties, as desired.
• The following Clauses provide an exemplary configuration for a sole structure and a method of forming a plate for an article of footwear described above.
• Clause 1: A sole structure for an article of footwear, the sole structure comprising: a component including a first bundle of fibers affixed to a substrate; a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element; and a resin consolidating the first bundle of fibers and entrapping the connecting member to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.
• Clause 2: The sole structure of Clause 1, wherein at least a portion of the connecting member is entangled in the first bundle of fibers.
• Clause 3: The sole structure of Clause 1, wherein at least one of the first traction element, the second traction element, and the connecting member includes a projection extending in a direction toward the substrate.
• Clause 4: The sole structure of Clause 3, wherein the projection is entangled in the fibers of the first bundle of fibers.
• Clause 5: The sole structure of Clauses 3 or 4, wherein the projection includes a retention feature operable to engage the fibers of the first bundle of fibers.
• Clause 6: The sole structure of Clause 5, wherein the retention feature includes at least one arm extending from a shaft, the shaft being received by and extending at least partially into the fibers of the first bundle of fibers.
• Clause 7: The sole structure of Clause 6, wherein the at least one arm is formed substantially perpendicular to the shaft.
• Clause 8: The sole structure of Clause 6, wherein the at least one arm is formed at an acute angle relative to the shaft.
• Clause 9: The sole structure of Clause 6, wherein the at least one arm extends from the shaft in a direction away from the substrate.
• Clause 10: The sole structure of Clause 6, wherein the shaft extends through a thickness of the first bundle of fibers.
• Clause 11: The sole structure of any of the preceding Clauses, wherein the connecting member is at least partially covered by the resin.
• Clause 12: The sole structure of any of the preceding Clauses, further comprising a third traction element attached to at least one of the first traction element and the second traction element by at least one additional connecting member.
• Clause 13: The sole structure of any of the preceding Clauses, wherein the first traction element and the second traction element are formed from nylon.
• Clause 14: The sole structure of any of the preceding Clauses, wherein the first bundle of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.
• Clause 15: The sole structure of any of the preceding Clauses, wherein the first bundle of fibers is stitched to the substrate via stitching.
• Clause 16: The sole structure of Clause 15, wherein the first bundle of fibers includes first fibers comingled with second fibers, the second fibers including at least one of a different length, thickness, melting temperature, and Young's modulus than the first fibers.
• Clause 17: The sole structure ofClause 16, wherein at least one of the stitching, the substrate, the first fibers, and the second fibers comprise a thermoplastic material.
• Clause 18: The sole structure of Clause 1, wherein at least one of the fibers of the first bundle of fibers and the substrate comprise a thermoplastic material.
• Clause 19: The sole structure of any of the preceding Clauses, wherein the resin is a polymeric resin.
• Clause 20: An article of footwear incorporating the sole structure of any of the preceding Clauses.
• Clause 21: The article of footwear ofClause 20, wherein the first traction element and the second traction element form a portion of a ground-engaging surface of the article of footwear.
• Clause 22: A method of forming a sole structure for an article of footwear, the method comprising: attaching a first bundle of fibers to a flexible substrate; forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element; consolidating the first bundle of fibers with resin; and entrapping the connecting member with the resin to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.
• Clause 23: The method ofClause 22, further comprising entangling at least a portion of the connecting member in the first bundle of fibers.
• Clause 24: The method ofClause 22, further comprising providing at least one of the first traction element, the second traction element, and the connecting member with a projection that extends in a direction toward the substrate.
• Clause 25: The method ofClause 24, further comprising entangling the projection in the fibers of the first bundle of fibers.
• Clause 26: The method ofClauses 24 or 25, wherein providing at least one of the first traction element, the second traction element, and the connecting member with a projection includes providing a projection having a retention feature operable to engage the fibers of the first bundle of fibers.
• Clause 27: The method of Clause 26, wherein providing a projection having a retention feature includes providing a retention feature having at least one arm extending from a shaft, the shaft being received by and extending at least partially into the fibers of the first bundle of fibers.
• Clause 28: The method of Clause 27, further comprising forming the at least one arm substantially perpendicular to the shaft.
• Clause 29: The method of Clause 27, further comprising forming the at least one arm at an acute angle relative to the shaft.
• Clause 30: The method of Clause 27, further comprising extending the at least one arm from the shaft in a direction away from the substrate.
• Clause 31: The method of Clause 27, further comprising extending the shaft through a thickness of the first bundle of fibers.
• Clause 32: The method of any of the preceding Clauses, further comprising at least partially covering the connecting member with the resin.
• Clause 33: The method of any of the preceding Clauses, further comprising providing the ground-engaging assembly with a third traction element attached to at least one of the first traction element and the second traction element by at least one additional connecting member.
• Clause 34: The method of any of the preceding Clauses, further comprising forming the first traction element and the second traction element from nylon.
• Clause 35: The method of any of the preceding Clauses, wherein attaching a first bundle of fibers to a flexible substrate includes attaching a first bundle of fibers including at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.
• Clause 36: The method of any of the preceding Clauses, further comprising stitching the first bundle of fibers to the substrate via stitching.
• Clause 37: The method of Clause 36, wherein attaching a first bundle of fibers to a flexible substrate includes attaching a first bundle of fibers including first fibers comingled with second fibers, the second fibers including at least one of a different length, thickness, melting temperature, and Young's modulus than the first fibers.
• Clause 38: The method of Clause 37, further comprising forming at least one of the stitching, the substrate, the first fibers, and the second fibers from a thermoplastic material.
• Clause 39: The method ofClause 22, further comprising forming at least one of the fibers of the first bundle of fibers and the substrate from a thermoplastic material.
• Clause 40: The method of any of the preceding Clauses, wherein consolidating the first bundle of fibers with resin includes consolidating the first bundle of fibers with a polymeric resin.
• Clause 41: The method of any of the preceding Clauses, further comprising incorporating the sole structure of any of the preceding Clauses into an article of footwear.
• Clause 42: The method of Clause 41, further comprising forming a portion of a ground-engaging surface of the article of footwear with the first traction element and the second traction element.
• Clause 43: The method of any of the preceding Clauses, wherein forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member includes forming the first traction element, the second traction element, and the connecting member using additive manufacturing.
• Clause 44: The method of any of the preceding Clauses, wherein forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member includes forming the first traction element, the second traction element, and the connecting member via three-dimensional (3D) printing.
• Clause 45: The method of any of the preceding Clauses, further comprising inserting the ground-engaging assembly into a first mold portion.
• Clause 46: The method of Clause 45, wherein inserting the ground-engaging assembly into the first mold portion includes inserting at least one of the first traction element, the second traction element, and the connecting member into a recess of the first mold portion.
• Clause 47: The method of Clauses 45 or 46, further comprising positioning the first bundle of fibers in contact with the ground-engaging assembly within the first mold portion.
• Clause 48: The method of Clause 47, further comprising compression molding the first bundle of fibers and the ground-engaging assembly to form the sole structure.
• Clause 49: The method of any of the preceding Clauses, wherein consolidating the first bundle of fibers with resin includes consolidating the first bundle of fibers with thermoplastic resin comingled with the first bundle of fibers.
• Clause 50: The method of Clause 49, further comprising applying heat to the first bundle of fibers to cause the thermoplastic resin to flow.
• Clause 51: A sole structure for an article of footwear, the sole structure formed by a process comprising the steps of: attaching a first bundle of fibers to a flexible substrate; forming a ground-engaging assembly including a first traction element, a second traction element, and a connecting member extending between and connecting the first traction element and the second traction element; consolidating the first bundle of fibers with resin; and entrapping the connecting member with the resin to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.
• Clause 52: The sole structure of Clause 51, wherein at least a portion of the connecting member is entangled in the first bundle of fibers.
• Clause 53: The sole structure of Clause 51, wherein at least one of the first traction element, the second traction element, and the connecting member includes a projection extending in a direction toward the substrate.
• Clause 54: The sole structure of Clause 53, wherein the projection is entangled in the fibers of the first bundle of fibers.
• Clause 55: The sole structure of Clauses 53 or 54, wherein the projection includes a retention feature operable to engage the fibers of the first bundle of fibers.
• Clause 56: The sole structure of Clause 55, wherein the retention feature includes at least one arm extending from a shaft, the shaft being received by and extending at least partially into the fibers of the first bundle of fibers.
• Clause 57: The sole structure of Clause 56, wherein the at least one arm is formed substantially perpendicular to the shaft.
• Clause 58: The sole structure of Clause 56, wherein the at least one arm is formed at an acute angle relative to the shaft.
• Clause 59: The sole structure of Clause 56, wherein the at least one arm extends from the shaft in a direction away from the substrate.
• Clause 60: The sole structure of Clause 56, wherein the shaft extends through a thickness of the first bundle of fibers.
• Clause 61: The sole structure of any of the preceding Clauses, wherein the connecting member is at least partially covered by the resin.
• Clause 62: The sole structure of any of the preceding Clauses, further comprising a third traction element attached to at least one of the first traction element and the second traction element by at least one additional connecting member.
• Clause 63: The sole structure of any of the preceding Clauses, wherein the first traction element and the second traction element are formed from nylon.
• Clause 64: The sole structure of any of the preceding Clauses, wherein the first bundle of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.
• Clause 65: The sole structure of any of the preceding Clauses, wherein the first bundle of fibers is stitched to the substrate via stitching.
• Clause 66: The sole structure of Clause 65, wherein the first bundle of fibers includes first fibers comingled with second fibers, the second fibers including at least one of a different length, thickness, melting temperature, and Young's modulus than the first fibers.
• Clause 67: The sole structure of Clause 66, wherein at least one of the stitching, the substrate, the first fibers, and the second fibers comprise a thermoplastic material.
• Clause 68: The sole structure of Clause 51, wherein at least one of the fibers of the first bundle of fibers and the substrate comprise a thermoplastic material.
• Clause 69: The sole structure of any of the preceding Clauses, wherein the resin is a polymeric resin.
• Clause 70: An article of footwear incorporating the sole structure of any of the preceding Clauses.
• Clause 71: The article of footwear of Clause 70, wherein the first traction element and the second traction element form a portion of a ground-engaging surface of the article of footwear.
• The foregoing description has been provided for purposes of illustration and description. It is not intended to be exhaustive or to limit the disclosure. Individual elements or features of a particular configuration are generally not limited to that particular configuration, but, where applicable, are interchangeable and can be used in a selected configuration, even if not specifically shown or described. The same may also be varied in many ways. Such variations are not to be regarded as a departure from the disclosure, and all such modifications are intended to be included within the scope of the disclosure.

Claims (20)

What is claimed is:

1. A sole structure for an article of footwear, the sole structure comprising:

a component including a first bundle of fibers affixed to a substrate;

a ground-engaging assembly including a first traction element, a second traction element, a connecting member extending between and connecting the first traction element and the second traction element, and a fastener projecting from at least one of the first traction element, the second traction element, and the connecting member in an opposite direction from each of the first traction element and the second traction element, the fastener including a shaft received by and extending at least partially into fibers of the first bundle of fibers and a retention feature disposed at an end of the shaft and extending in a first direction away from the shaft, the retention feature operable to engage the fibers of the first bundle of fibers; and

a resin consolidating the first bundle of fibers and entrapping the connecting member and the fastener to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.

2. The sole structure ofclaim 1, wherein at least a portion of the connecting member is entangled in the first bundle of fibers.

3. The sole structure ofclaim 1, wherein the retention feature includes at least one arm extending in the first direction away from the shaft.

4. The sole structure ofclaim 3, wherein the at least one arm is formed substantially perpendicular to the shaft.

5. The sole structure ofclaim 3, wherein the at least one arm is formed at an acute angle relative to the shaft.

6. The sole structure ofclaim 3, wherein the at least one arm extends from the shaft in a direction away from the substrate.

7. The sole structure ofclaim 3, wherein the shaft extends through a thickness of the first bundle of fibers.

8. The sole structure ofclaim 1, wherein the connecting member is at least partially covered by the resin.

9. The sole structure ofclaim 1, wherein the first bundle of fibers includes at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers.

10. An article of footwear incorporating the sole structure ofclaim 1.

11. A method for forming a sole structure for an article of footwear, the method comprising:

attaching a first bundle of fibers to a substrate;

extending a shaft of a fastener at least partially into fibers of the first bundle of fibers, the fastener projecting from at least one of a first traction element, a second traction element, and a connecting member joining the first traction element and the second traction element to define a ground-engaging assembly;

providing the shaft with a retention feature disposed at an opposite end of the shaft than the at least one of the first traction element, the second traction element, and the connecting member, the retention feature extending in a first direction away from the shaft;

engaging the fibers of the first bundle of fibers with the retention feature; and

consolidating the first bundle of fibers and entrapping the connecting member and the fastener with a resin to fix a position of the first traction element, the second traction element, and the connecting member relative to the substrate.

12. The method ofclaim 11, further comprising entangling at least a portion of the connecting member in the first bundle of fibers.

13. The method ofclaim 11, further comprising providing the retention feature with at least one arm that extends in the first direction away from the shaft.

14. The method ofclaim 13, further comprising forming the at least one arm substantially perpendicular to the shaft.

15. The method ofclaim 13, further comprising forming the at least one arm at an acute angle relative to the shaft.

16. The method ofclaim 13, further comprising extending the at least one arm from the shaft in a direction away from the substrate.

17. The method ofclaim 11, further comprising extending the shaft through a thickness of the first bundle of fibers.

18. The method ofclaim 11, further comprising at least partially covering the connecting member with the resin.

19. The method ofclaim 11, wherein attaching the first bundle of fibers to the substrate includes attaching at least one of carbon fibers, boron fibers, glass fibers, and polymeric fibers to the substrate.

20. Further comprising incorporating the sole structure ofclaim 11 into an article of footwear.

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